Methods and systems for converting waste into complex hydrocarbons

ABSTRACT

A method for receiving animal waste from animal confinements or other concentrated animal waste sources and for converting the waste into a complex hydrocarbon is described. The waste contains both liquids and solids. The method includes separating the liquids and solids into separate waste streams, controlling an amount of moisture in the solids waste stream such that the amount of moisture in the solid waste stream is compatible with a selected energy conversion process, and feeding the moisture controlled solid waste into the energy conversion process. The complex hydrocarbon may be suitable for use as a substitute or additive to petroleum-based asphalt binder.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a Continuation-in-Part of U.S. patent applicationSer. No. 11/506,011 (now U.S. Pat. No. 7,597,812) entitled “Methods andSystems for Converting Waste Into Energy”, filed Aug. 17, 2006, which isa Divisional of U.S. patent application Ser. No. 10/812,153, (now U.S.Pat. No. 7,105,088) entitled “Methods and Systems for Converting WasteInto Energy”, filed Mar. 29, 2004. The disclosures of said applicationsare incorporated by reference in their entirety.

BACKGROUND OF THE INVENTION

This invention relates generally to the problems associated with wastein animal confinements, and more specifically, to methods and systemsfor converting the resulting high concentrations of animal waste intocomplex hydrocarbons suitable for other uses.

Animals have been raised for centuries for food. Previously animalsgrazed in fields or pens, and were at times confined to buildings forshelter. However, current state of the art animal production for swine,cattle, and other animals, includes housing large numbers of suchanimals in high concentration within confined buildings, and deliveringfood to the animals. This method of animal production has benefitedconsumers of meat by lowering food prices through increased efficiency.A drawback to the current methods of animal production includes theresulting high concentration of wastes that have to be removed from thebuildings and disposed of in a safe manner.

Typically, the waste is removed from animal confinement buildings anddeposited into large lagoons. Once within these lagoons, which can bemulti-acre in size, the waste decomposes. The solid and liquid wastes inthe lagoons cause an odor problem for the surrounding area, both as itdecomposes in the lagoon, and during field application as a fertilizeras further described.

After partially decomposing, the waste from the lagoons is applied toland (e.g. fields where crop are grown) as a fertilizer. The potentialfor environmental contamination during field application of the waste issubstantial and many fields in pork producing states have been overfertilized. In addition, some of the applied fertilizer can becomewindborne during application and is therefore a source of environmentalcontamination for adjacent areas.

There are also additional weaknesses with waste lagoon technology,specifically, collapsed walls and ground leaching, both of which cancontribute to waterway and well contamination. In a recent EPA report,60% of the US streams identified as “impaired” were polluted by animalwastewater. Animal wastewater management has become a high priority forthe EPA.

Still another problem with current animal production methods is that aircycled through the confinement buildings to keep the animals cool isblown into the atmosphere through the fans at the end of theseconfinement buildings. This is another source of airborne waste inaddition to the fertilizer application problems described above. Anotherproblem caused in part by the airborne waste is an increasedsusceptibility to respiratory and other health problems in farm workers.Legislative pressures have forced at least one state to impose amoratorium on new swine confinements, and other states are predicted tofollow.

There have been numerous attempts to improve the current state of theart in animal production, but most of these attempts still includedrawbacks. For example, some still require a waste lagoon. Anothersystem uses an inclined belt to concentrate solids percentage of waste,but does not eliminate or gain beneficial results from the solid waste.Other systems are known in which the wastes are eliminated by burning,but the burning of such wastes is not utilized to provide a beneficialresult. Other systems treat waste through chemicals, but the waste isreturned to the environment as a dried sludge. Additionally, anaerobicdigestion systems exist.

There are additionally several energy conversion processes known butthese systems do not describe any methods for getting the waste to theconversion system, nor the overall process of handling the animal waste.

BRIEF DESCRIPTION OF THE INVENTION

In one aspect, a system for processing a waste stream from animalproduction confinements and other sources of concentrated wastes andconverting it into a complex hydrocarbon is provided. The systemcomprises a solids/liquids separator receiving the waste stream andconfigured to separate the waste stream into a solid waste stream and aliquid waste stream and a water treatment apparatus for treating theliquid waste stream. The system further comprises a control system forcontrolling an amount of moisture in the solid waste stream, an energyconversion processor receiving the moisture controlled solid wastestream and converting the solid waste stream into the complexhydrocarbon.

In another aspect, a method for receiving animal waste from animalconfinements or other concentrated animal waste sources and convertingthe waste into a complex hydrocarbon is provided. The waste containsliquids and solids and the method comprises separating the liquids andsolids into separate waste streams and controlling an amount of moisturein the solids waste stream such that the amount of moisture in the solidwaste stream is compatible with an energy conversion process. The methodfurther comprises feeding the moisture controlled solid waste into theenergy conversion process, wherein the energy conversion processconverts the moisture controlled solid waste stream into the complexhydrocarbon.

According to another aspect, a complex hydrocarbon is provided that isproduced from a waste stream from animal production confinements andother sources of concentrated waste. The complex hydrocarbon is producedby a method comprising the steps of separating the liquids and solidsinto separate waste streams and controlling an amount of moisture in thesolids waste such the amount of moisture in the solid waste stream iscompatible with an energy conversion process. The moisture controlledsolid waste stream is then fed into the energy conversion process. Theenergy conversion process is adapted to convert the moisture controlledsolid waste stream into the complex hydrocarbon that is configured foruse as an asphalt additive or substitute.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an overall conversion process diagram of a system forconverting a waste stream into a fuel source, including a solids/liquidsseparator.

FIG. 2 is a block diagram of a portion of the system of FIG. 1,including an embodiment of a solids/liquids separator for a waste streamincluding a high solids concentration.

FIG. 3 is a block diagram of a portion of the system of FIG. 1,including an embodiment of a solids/liquids separator for a waste streamincluding a low solids concentration.

FIG. 4 is a block diagram of a portion of the system of FIG. 1,illustrating an embodiment having multiple mechanical solids/liquidsseparators.

FIG. 5 is a block diagram of a portion of the system of FIG. 1,illustrating an embodiment having multiple gravity solids/liquidsseparators.

FIG. 6 is a block diagram of a portion of the system of FIG. 1,illustrating an embodiment of a heat and gas recovery sub-system.

FIG. 7 is a block diagram of a portion of the system of FIG. 1,illustrating an embodiment having multiple gravity solids/liquidsseparators routed to a mechanical separator.

FIG. 8 is a block diagram of one embodiment of an energy conversionprocessor.

FIG. 9 is a block diagram of is an overall conversion process diagram ofa system for converting a waste stream into a complex hydrocarbon.

FIG. 10 is a block diagram of a portion of the system of FIG. 1,including an embodiment with a dual cylinder pump for pumping the wastestream.

FIG. 11 is a flow diagram depicting a method of pumping a slurry intothe energy conversion processor and receiving an effluent as output fromthe energy conversion processor, in accordance with another embodimentof the present invention

DETAILED DESCRIPTION OF THE INVENTION

The systems herein described provide methods for handling raw animalwaste and converting the waste into fuel, which may then be used forheat, transportation, or preferably direct conversion to power through agenerator driven by an engine or combustion turbine.

Referring to FIG. 1, animal confinement 10 includes a manure collectionarea 12 for the collection of wastes and flushing water. The wastes andflushing water are transported to solid/liquid separator 14 utilizing atransporting mechanism 16. In one embodiment, transporting mechanism 16operates by gravity, but other embodiments of transporting mechanism 16exist which may also use pumps and/or conveyors in addition to orinstead of gravity to transport animal waste and other accompanyingmaterials. As used herein, the term “transport” is utilized to describemethods for moving mass from one location to another, including, but notlimited to, pumping, gravity, auger, conveyor, and the like.

In a specific embodiment, a positive displacement pump designed for highsolids contents is utilized for transporting animal waste fromcollection area 12 to solid/liquid separator 14. One positivedisplacement pump is a grinding pump, one example of which is a MoynoL-Frame progressing cavity pump.

Solid/liquid separator 14 may include one or more mechanical and gravityseparators which are further described below. A gravity separator issometimes referred to as a settling tank. In one embodiment,solid/liquid separator 14 is utilized to deliver volatile solids fromthe waste, which have a significant BTU content for use as fuel, to anenergy conversion processor 20. As further described below, the solidwastes are delivered to energy conversion processor 20 within aspecified range of moisture content.

The animal waste exiting manure collection area 12 is typically about97% to about 99.5% liquid. This is a result of manure by nature beingvery wet. Additional moisture is added due to urine and the water usedto flush the animal waste from confinement 10. Small additional amountsof water are contributed to the animal waste by sloppy drinking andanimal cleaning. Hog manure, for example, is typically about 80%-90%liquid by weight.

Each embodiment of energy conversion processor 20 has a range for themoisture content of the solid waste being converted that enables properconversion of the solid waste. For example, the well-known gasificationprocess typically requires a relatively dry feedstock, for example, afuel with about a 20% to about a 30% moisture level. By contrast, otherconversion processes such as liquification or pyrolysis allow muchwetter feedstock streams, up to about an 80% moisture level.

As described above, the animal waste is transported into energyconversion processor, which may use pyrolysis, gasification, or one of anumber of related conversion processes that utilize controlledtemperature, pressure, and time to convert the waste into a one of afuel gas, an oil, a solid, or a combination thereof. The convertedanimal waste is referred to herein as “fuel”.

From energy conversion processor 20, the fuel is filtered and processedby filter processor 22 as necessary for usage. In one embodiment, thesystem includes one or more optional fuel storage tanks 24, or buffertank(s). The fuel is then converted into electricity through a knowndevice such as an engine or turbine-driven generator 26.

In the embodiment illustrated, a second power generator 28 isillustrated. In many locations, electrical power is more valuable during“peak demand” periods. One feature of the system illustrated is thatpower generator 26 is utilized to supply a certain quantity of power,while second power generator 28 supplies another quantity. Powergenerator 26 and second power generator 28 may provide equal power ormay provide different power amounts (i.e., be differently sized). In aparticular embodiment, power generator 26 supplies electricity andengine heat sufficient to keep the processes of the illustrated systemcontinuously running except for maintenance. Second power generator 28is turned on when power demand is at a peak. In a specific embodiment,power generator 26 is a Kohler 150REOZV and second power generator 28 isa Kohler 500REOZV.

Operation of second power generator 28, in one embodiment, is controlledby a controller 30, which includes a timer (not shown), operating inconjunction with a level controller 32, having a sensor input 34.Controller 30 may also be controlled remotely by a remote signal 36 froma utility or an operator of the energy conversion system illustrated.This operation enables the energy conversion system to meet electricalload demand and also maximize economic benefit to the system's owner.Such operation provides benefits to the public and the electrical gridoperators by reducing loading on transmission lines, by providingdemand-based distributed generation. Additionally, fuel production willvary due to fluctuations in manure production and other factors. Thetwin power generator arrangement provides a solution for thefluctuations in fuel supply while allowing generators to run at peakefficiency.

There is typically wastewater generated by the energy conversion systemin the conversion process, either within energy conversion processor 20or in filter/processor 22. This wastewater is transported, by pumpand/or gravity, to a water treatment apparatus 40, which removes anyremaining entrained solids, liquids and gases to levels approved by theapplicable authorities. Water from water treatment apparatus 40 iseither discharged to water bodies, or used for crop irrigation, or anynumber of other useful purposes that displace water currently taken fromground sources and/or water bodies.

In a particular embodiment, the water is transported back to confinement10 for a variety of purposes. As illustrated in FIG. 1, a holding tank42 has a level control valve 44 that allows holding tank 42 to fill asneeded. A control valve and/or pump 46 transmits the water through aflush line 48 into manure pit 12 as needed in order to provide theflushing water needed to clean manure out of confinement 10.

In one embodiment, water is also pumped to devices which filter the airexiting confinement 10 via ventilation system 50. An example of such adevice is an air scrubber 52 as described in U.S. Pat. No. 6,059,865.Water washes down an inclined plate (not shown) of air scrubber 52, asventilation fans blow against the inclined plate. Odor containingparticles and gases are captured within the water stream. This water isshown as being returned to holding tank 42. The water can alternately bereturned to water treatment apparatus 40 or utilized directly forflushing of manure pit 12.

FIG. 2 illustrates one embodiment of solid/liquid separator 14 (shown inFIG. 1). Certain energy conversion processes utilize a low moisturelevel, for example, gasification. In such energy conversion processes,solid/liquid separator 14 may include one or more mechanical separators60. Individual mechanical separators 60 may be a type of press (e.g., abelt press), an auger, a conveyor, a centrifuge, a hydrocyclone, ascreen separator, or another type of mechanical separator, alone, or inconjunction with one or more other mechanical separators that work inconjunction to remove substantially all of the useful volatile solidsfrom the waste. At least some known mechanical separation equipmentleaves much of the useful volatile solids in the wastewater.

In the embodiment of solid/liquid separator 14 illustrated in FIG. 2,any solids retained in the waste are forwarded from mechanical separator60 to settling tank 62, either by gravity and/or by pumping. Someexamples of mechanical separator 60 are the KCS&C 48X30 Centrifuge, orVincent KP-6L Screw Press. Settling tank 62 allows the retained solidsto gravitate toward a bottom 64 of a fixed tank, while the liquidportion is forwarded for water treatment 66. In additional embodiments,settling tank 62 may include more than one settling tank in series orparallel. The solids that gravitate toward bottom 64 of settling tank 62are transported back to mechanical separator 60, either directly, or toa buffer tank 68, as illustrated in FIG. 2.

The solids stream from mechanical separator 60 are forwarded, in oneembodiment, to a shredder 70. A shredder 70 may not be needed for someanimal waste streams, and its function may be replaced by a standardpump or a grinding pump. The waste is then transported, either by pumpor gravity, to a dryer 72. In the embodiment shown in FIG. 2, dryer 72is a helical auger in which heat and/or air is added to the unit,lowering the moisture content of the waste to meet the operatingconditions of energy conversion processor 20. In the embodiment shown,moisture content of the waste is controlled by a moisture sensor 74 thatmonitors the amount of heat and airflow entering dryer 72. Moisturesensor 74 provides an analog or digital signal to the moisturecontroller (MIC) 76. Moisture controller 76 is configured to vary aprocess variable to control the moisture level of the waste withinpre-defined limitations for use by energy conversion processor 20. Aparticular embodiment utilizes an Omega CDCE-90-1 moisture sensor, andan Omega CDCN-90 moisture controller. In this embodiment, moisturesensor 74 provides a proportional signal to moisture controller 76. Anoutput of moisture controller 76 is utilized to control devicesaffecting the moisture percentage of the waste.

In particular embodiments, if moisture sensor 74 indicates that themoisture percentage is too high to be processed properly by energyconversion processor 20, then a hot air flow that is applied to thewaste stream entering energy conversion processor 20 is increased. Thehot air may be generated utilizing a variety of methods and oneexemplary embodiment is illustrated in FIG. 2, where a coolant 80 from apower generator 82 is passed through a heat exchanger 84, where heat istransferred to the incoming air in order to raise its temperature, whichincreases its capacity to remove moisture from the process stream. Avariable speed blower 86 has a variable frequency drive or othermodulating device such as a mechanical damper, that is controlled by thesignal output by moisture controller 76. In a specific embodiment, heatexchanger 84 is a pipe-in-pipe heat exchanger manufactured by a varietyof other manufacturers and blower 86 is manufactured by the New YorkBlower Company.

In other embodiments, drying methods include raising the temperature ofthe waste through electric or fuel fired heaters or heat exchanged fromother higher temperature areas of the process via fluid, gas or steamheat exchange media. Alternately, gases from engine exhaust of powergenerator 82 or energy conversion processor 20 can be utilized directly,similarly to the hot air embodiment above described.

In one embodiment, dryer 72 includes a perforated top screen (not shown)which allows the warmed moist air to escape. In other embodiments, theairflow is constant, but the amount of heat is varied, for example by athree-way valve modulating the amount of hot engine fluid (e.g., coolant80) delivered to heat exchanger 84. Alternately other process variablessuch as rotation speed of dryer 72 or temperature of heating media maybe controlled to obtain the same effect. Other heat sources may be used,such as engine exhaust from power generator 82, heat from energyconversion processor 20, heat from the process stream 88 after energyconversion processor 20, solar-heated thermal fluid, or heat from aseparate combustion process, such as burning paraffins separated fromthe resultant fuel.

FIG. 3 illustrates an alternate embodiment where energy conversionprocessor 20 is configured to utilize or allow higher moisture contentfeedstock (e.g., animal waste streams). In this embodiment, a portion ofthe solids stream from settling tank 62 is delivered to the line whichcontains the solid portion from mechanical separator 60. The amount ofthis stream from settling tank 62 is controlled by moisture controller(MIC) 76, based on an input from moisture sensor 74 or a similarinstrumentation means. Alternately the amount of solids from settlingtank 62 is controlled by simple experimental manual balancing. In theembodiment illustrated a three way control valve 100 and moisture sensor74 are used to control the amount of solids from settling tank 62 intothe waste stream. Alternatively one or more two-way control valves orsolenoid operated valves may be utilized.

The waste stream is exposed to heat from heat exchanger 84 before entryinto energy conversion processor 20. The heat for heat exchanger 74 maybe provided from a variety of sources. In a specific embodiment, heatmay be provided to heat exchanger 84 from a power generator (shown inFIG. 1) from one or more of exhaust and engine cooling water. The wastestream in effect replaces the engine's radiator, in part or in whole.Additional heat sources may be used such as solar thermal, electric heatrun by the unit's generator or other power source, or direct firing of aportion of the fuel, or waste fractions of the fuel. The heated waste isthen transported to energy conversion processor 20 and processed asdescribed with respect to FIG. 1.

FIG. 4 illustrates an alternate embodiment of a solids/liquids separator110 for energy conversion system which increases efficiency ofseparation between solids and liquids in the waste stream. In additionto mechanical separator 60, a second mechanical separator 112 isincluded. Mechanical separator 60 and second mechanical separator 112may be of the same type of construction, but in a specific embodiment,mechanical separator 60 is a highly energy efficient type separator, forexample, a press, while second mechanical separator 100 is a more energyintensive separator, such as a centrifuge. In the embodiment, secondmechanical separator 112 processes less mass flow than does mechanicalseparator 60 thereby raising overall efficiency of the energy conversionsystem. Specifically, mechanical separator 60 directs the high-solidsfraction of the waste towards energy conversion processor 20, while ahigh-liquids fraction of the waste is transported to second mechanicalseparator 112. Second mechanical separator 112 also directs itshigh-solids fraction toward energy conversion processor 20, while thehigh-liquids fraction is directed to settling tank 62. From settlingtank 62, a high-solids fraction of the waste is directed back to buffertank 68 or alternately to one or both of mechanical separators 60, 112and another fraction is transported toward energy conversion processor20. Three-way valve 100, which is controlled by moisture controller(MIC) 76, based on the input from moisture sensor 74. Three-way valve100 varies the amount of high-solids waste fraction transported towardeither energy conversion processor 20 and buffer tank 68, or alternatelybetween first and second mechanical separators 60, 112.

FIG. 5 illustrates another embodiment of a solids/liquids separator 120for energy conversion system which also increases efficiency ofseparation between liquids and solids in a waste stream. Solids/liquidsseparator 120 includes a second settling tank 122, which may be of thesame type of construction as settling tank 62, but typically will have adifferent geometry. Settling tank 122 directs the high-solids fractionof the waste towards energy conversion processor 20, while thehigh-liquids fraction of the waste from second settling tank 122 istransported to settling tank 62. Settling tank 62 transports itshigh-liquids fraction to waste water treatment (e.g., apparatus 40 shownin FIG. 1). The prime advantages of gravity separation utilizingsettling tanks are low energy consumption and high recovery of solids.Putting two gravity separators in series (i.e., settling tanks 62 and122) downstream of mechanical separator 60 is thought to recoverapproximately 97% of the solids. The high-solids fractions of waste fromboth gravity separators 62, 122 are transported back to buffer tank 68or combined with an output from mechanical separator 60 and directed toshredder 70 and onto energy conversion processor 20. A three-way valve124 operates in the same fashion as three way valve 100 described above,that is, controlled by moisture controller (MIC) 76, based on an inputfrom moisture sensor 74. Three-way valves vary an amount of high-solidswaste transported toward energy conversion processor 20, buffer tank 68,and mechanical separator 60.

For all of the above described embodiments, it should be easilyunderstood that many variations can be made and still be within thespirit and scope herein described. For example, altering thearrangements and quantity of separators, such as three or moreseparators in a parallel or series-parallel arrangements are certainlycontemplated.

FIG. 6 displays one embodiment of a heat recovery system 140 which maybe utilize to improve and/or optimize the processes performed by theenergy conversion system. In the illustrated embodiment, the wastestream is heated via heat recovered from the cooling fluid of powergenerator 142, typically a glycol/water mix, via heat exchanger 144. Thewaste is further heated in a second heat exchanger 146, using steamand/or exhaust gases available from energy conversion processor 20.These may alternately be taken from a vessel within energy conversionprocessor 20 or a downstream apparatus such as a flash tank as utilizedin the petroleum industry.

Another source of heat recovery is shown which circulates a heattransfer medium through heat exchangers 148, 150. The heat transfermedium transfers heat from the hot fuel from energy conversion processorto the incoming waste stream, preheating it, raising overall efficiency.

Additional process control instrumentation is also illustrated in FIG. 6by way of example only. Recovery of constituents of exhaust gases isimportant with certain embodiments of energy conversion processor 20.For example, one embodiment of energy conversion processors requirecarbon monoxide (CO) and/or carbon dioxide (CO2), which are readilyavailable in significant quantities from the exhaust of an engine and/orcombustion processes. In the embodiment shown, a portion of the exhaustgas is separated by gas separator 152 for delivery to energy conversionprocessor 20. The exhaust gas may be filtered, or chemically converted(for example converting CO2 into CO and O2) to deliver the desired gasor gases to energy conversion processor 20. In one embodiment, membranetechnology is utilized within gas separator 152 to concentrate theamount of one gas, for example CO, for delivery into the process. Othermore complex gas separation methods such as pressure-swing absorption,vacuum swing absorption, chemical separation, catalytic separation, andother gas separation methods may be utilized to accomplish the same goalof delivering a more desirable mix of gas to energy conversion processor20. The gas separation process typically utilizes a compressor for thefeed gas (exhaust), or one or more vacuum pumps.

FIG. 7 illustrates another embodiment for a solids/liquids separator 170for an energy conversion system which controls a solids percentage,primarily for a low-solids energy conversion processor 20.Solids/liquids separator 170 includes one or more gravity separators(settling tanks 62, 122 shown). The high-solids fraction of the wastefrom each settling tank 62, 122 is transported toward energy conversionprocessor 20, except that a fraction of the high-solids fraction isdirected through mechanical separator 60, which raises the solidspercentage of the waste to a desired level for input into energyconversion processor 20. A three-way valve 172 is controlled by themoisture controller (MIC) 76, based on an input from moisture sensor(MT) 74. Three-way valve 172 could alternately be a combination oftwo-way valves and/or manual valves. The liquid fraction of the wastefrom mechanical separator 60 can alternately be transported to buffertank 68 or directly to one of settling tanks 62, 122.

FIG. 8 illustrates one example of an energy conversion processor 200. Inthe example illustrated, pump 202 raises pressure of the waste withinenergy conversion processor 200. As described above, the waste has beencontrolled to a specified moisture level. The waste is pumped through alength of tubing 204. An example includes 1000′ of 1.5 inch NPS Schedule80 304ss with an inside diameter of about 1.5″, which coiled in about a12 foot diameter, with 27 turns. A flowrate of approximately 4.6 gpm ispumped into energy conversion processor 200. A step down transformer 206converts 480 volt, single phase power from power 208 generator to a lowvoltage, for example 30 VAC. Temperature sensor 210 provides a signal totemperature controller 212. The amount of power from power generator 208delivered to energy conversion processor 200 is controlled by powercontroller 214. Power controller 214, in one embodiment, is the phaseangle SCR (Silicon Controlled Rectifier) type or another similar type. Aspecific SCR type power controller is supplied by EuroTherm. Powercontroller 214 delivers an amount of power to step down transformer 206proportional to the signal received from temperature controller 212.Power controller 214 regulates the voltage applied to the primary oftransformer 206, which regulates the voltage applied to energyconversion processor 200 by the same ratio. Such an arrangementmaintains the temperature of the waste at the outlet 216 of energyconversion processor 200. Another embodiment, not shown, utilizesmultiple zones, for example, two transformers 206, two power controllers214, two temperature sensors 210, and two temperature controllers 212,where each zone may have differing temperature setpoints or the sametemperature setpoint to have a zone of temperature rise rather then azone of maintaining temperature.

In one embodiment, tubing 204 of energy conversion processor 200includes a jacketed pipe wherein heat from a power generator is appliedas one of heated fluid or heated gas to the jacketed pipe to maintaindesired temperature setpoints. In this and other embodiments, heat froma power generator is therefore applied to the waste stream within energyconversion processor (20, 200) by one or more of impedance andinduction, in one or more distinct zones of heating.

The above described embodiments are utilized to control an amount ofmoisture within a waste stream to attempt to provide an optimum wastefor the particular energy conversion processor 20. When energyconversion processor 20 is a gasification processor, a moisturepercentage entering mechanical separator 60, for example, an inclinedscrew press, is about 95%. The moisture percentage in the high-solidsstream exiting mechanical separator 60 is about 65%. The mass fractionof solids forwarded to shredder 70 is then about 30%. The remaining 70%mass fraction of waste is forwarded to a gravity separator (e.g.,settling tank 62). The solid fractions in the gravity separator arecontinually recycled to buffer tank 68, where it is mixed with freshslurry and reintroduced into mechanical separator 60. For the wastestream exiting shredder 70, hot air is introduced into dryer 72 (shownin FIG. 2, and is regulated as described above to reduce the moisturepercentage in the waste stream being fed to energy conversion processor20 to about 25%.

When energy conversion processor 20 is a pyrolysis or liquificationprocessor, a moisture percentage entering mechanical separator 60, forexample, a solid bowl basket centrifuge, is about 97%. The moisturepercentage in the high-solids stream exiting mechanical separator 60 isabout 72%. The mass fraction of solids forwarded to shredder 70 is thenabout 65%. The remaining 35% mass fraction is forwarded to a gravityseparator (e.g., settling tank 62). The moisture percentage of the solidfraction in the gravity separator is about 90%. The flow from gravityseparator is divided at a three-way valve, with nominally 50% of theflow directed to the pipe connecting mechanical separator 60 andshredder 70. This results in a desired mixture moisture percentage ofabout 80% in this case. The three-way valve position is regulated aspreviously described, to maintain this moisture percentage setpoint. Theremaining high-solids stream from the gravity separator is continuallyrecycled to buffer tank 68, where it is mixed with fresh slurry andreintroduced into the mechanical separator.

The above described embodiments and examples serve to illustrate howcontrol of moisture content from a waste stream is utilized by a numberof different energy conversion processor types in order to provide amethod for disposing of and gaining beneficial use from animalproduction waste streams. The above described embodiments also do notinvolve methods that contribute to odor released into the atmosphere,providing a more desirable approach to the problem of animal productionwaste than known solutions which include lagoons and field spreading.

While the above-described embodiments relate to the creation of fuelsources from the waste stream and subsequent use of the fuel sources forpower generation, alternative embodiments utilize the energy conversionprocessor 20 to create complex hydrocarbons, which may be output to, forexample, hydrocarbon storage 25 (shown in FIG. 9). Whether the energyconversion processor 20 converts the waste stream into a fuel source, asdescribed in FIGS. 1-8, or a complex hydrocarbon adapted for other uses,as described in relation to system depicted in FIGS. 9 and 10, isdependent on a number of factors. For example, the temperature and/orpressure within the energy conversion processor 20 may be altered oradditional substances may be input to the processor, according to someembodiments, in order to affect the chemical composition of the output(i.e., complex hydrocarbon) generated by the energy conversionprocessor.

The complex hydrocarbons generated by energy conversion processor 20 inthe system of FIG. 9 are adapted to be suitable for a variety ofapplications. In one embodiment, these complex hydrocarbons are suitableto be used as an additive to, or substitute for, bitumen andpetroleum-based asphalt binder.

Asphalt, as described herein is a composition of an asphalt bindermixture and an aggregate. The asphalt binder mixture binds the aggregatetogether. The asphalt binder mixture may contain one or more of thefollowing (each of which is discussed in greater detail below): apetroleum-based asphalt binder, a polymer-based asphalt binder additive,or the complex hydrocarbon generated by the energy conversion processor20 of FIG. 9.

Bitumen is a naturally occurring, viscous mixture of hydrocarbons, oftenfound as a hydrocarbon-rich mixture in sand, clay, and water. Bitumenmust first be extracted from the mixture in which it is found (i.e.,sand, clay, or water) and processed before transportation to a petroleumrefinery for further processing. The petroleum-based asphalt binder isbut one of several mixtures of hydrocarbons in the bitumen class. Itpossesses strong weather and chemical resistance and is often used inpaving applications or roofing applications (e.g., tar or asphalt-basedshingles). Petroleum-based asphalt binder is derived from crude oilduring the petroleum refining process. Of the fractions contained withina barrel of oil, petroleum-based asphalt binder is the bottom fractionthat remains after all of the other fractions have been removed in therefining process.

Currently, petroleum-based asphalt binder is produced almost exclusivelyby petroleum refineries. The properties of the crude oil fed into thepetroleum refineries often vary considerably. Accordingly, theproperties of the asphalt binder produced from the crude oil vary aswell. In order to account for the differences in properties ofpetroleum-based asphalt binder, polymer-based asphalt binder additivesare often mixed with it, resulting in an asphalt binder mixture ofmaterials that have substantially uniform properties. Different types oramounts of the polymer-based asphalt binder additives are mixed with thepetroleum-based asphalt binder based on the properties of thepetroleum-based asphalt binder in order to achieve an asphalt bindermixture that has substantially uniform properties.

Polymer-based asphalt binder additives are also capable of enhancing theperformance characteristics of petroleum-based asphalt binder (e.g.,improved high-temperature stiffness and increased low-temperatureelasticity). Many polymer-based asphalt binder additives are derivedfrom polymers produced from crude oil during a secondary chemicalprocess. A commonly used polymer-based asphalt binder additive isstyrene-butadiene-styrene (SBS).

In one exemplary embodiment, the system of FIG. 9 generates a complexhydrocarbon that is suitable for use as either a substitute forpetroleum-based asphalt binder or polymer-based asphalt binder additive,or suitable for insertion as a feedstock into heavy oil streams (e.g.,vacuum distillation or coker units) at a petroleum refinery. The complexhydrocarbon is generated by the system of FIG. 9 by subjecting the wastestream to a specific temperature and pressure within the energyconversion processor 20 over a prolonged period of time (e.g., thirtyminutes to two hours). The complex hydrocarbon generated by the energyconversion processor 20 and the specific temperature and pressuretherein has material properties similar to a petroleum-based asphaltbinder.

In such an exemplary embodiment, the complex hydrocarbon generated bythe specific temperature and pressure within the energy conversionprocessor 20 in system of FIG. 9 has a specific gravity, pour point,viscosity, and a heat of combustion similar (collectively referred to as“material properties”) to that of petroleum-based asphalt binder.

The values of the material properties of the complex hydrocarbongenerated by the energy conversion processor 20 can be changed by eitheraltering the conditions within the energy conversion processor 20 or thecontent of the material input to the energy conversion processor. Forexample, the specific gravity of the complex hydrocarbon may bedecreased by introducing hydrogen to the energy conversion processor 20during the process carried out within the energy conversion processor.The hydrogen may be “bubbled” or injected into the energy conversionprocessor 20 in a gaseous form by a hydrogen injection mechanism. Thehydrogen injection mechanism is in fluid communication with a source ofhydrogen and serves to regulate the flow and pressure of hydrogen inputto the energy conversion processor 20. Included in the hydrogeninjection mechanism may be one or more valves, pipes, fittings, orconnectors.

When introduced within the energy conversion processor 20, the hydrogenmay reduce the length of hydrocarbon chains which make up the complexhydrocarbon by breaking off organic chains from the complex hydrocarbon.The corresponding reduction in the length of the chains serves todecrease the specific gravity, pour point, and viscosity while alsoincreasing BTUs per pound of the complex hydrocarbon.

The length of the chains comprising the complex hydrocarbon is believedto be reduced by increasing the temperature and/or pressure within theenergy conversion processor 20 with or without the introduction ofhydrogen to the processor. Conversely, the length of the chains isbelieved to be increased by decreasing the temperature and/or pressurewithin the energy conversion processor 20. Accordingly, when one or anycombination of the temperature, pressure, or residence time isincreased, the carbon chains may be reduced in length compared to whenone or any combination of the values is reduced.

While specific mention has been made to the similarity of the materialproperties of the complex hydrocarbon to those of a petroleum-basedasphalt binder according to the exemplary embodiment, they should not beconstrued as limiting. To the contrary, a wide variety of complexhydrocarbons with varying properties may be generated by the system ofFIG. 9 by altering the pressure and temperature within the energyconversion processor 20. Accordingly, the ranges and values presentedherein are intended to be illustrative only and represent the materialproperties of but one complex hydrocarbon generated according to aspecific temperature and pressure within the energy conversion processor20.

According to some embodiments, the complex hydrocarbon may besubstituted for a portion or all of the petroleum-based asphalt binderin an asphalt mixture. For example, the amount of petroleum-basedasphalt binder may be reduced by a measure, and replaced by an equalmeasure of the complex hydrocarbon generated by the energy conversionprocessor 20. For example, the amount of petroleum-based asphalt binderin the asphalt mixture may be reduced by an amount (e.g., an amountaccounting for 25% by weight of the petroleum-based asphalt binder) andan amount of the complex hydrocarbon substantially equal to the reducedamount may be added to the asphalt mixture. According to one exemplaryembodiment, a first asphalt mixture may contain 1000 pounds ofpetroleum-based asphalt binder. In a second asphalt mixture mixedaccording to one embodiment, the amount of petroleum-based asphaltbinder may be reduced to 750 pounds, and 250 pounds of complexhydrocarbons generated by the system of FIG. 9 may be substituted inplace of the 250 pounds of petroleum-based asphalt binder. Other ratiosare contemplated as well, with some embodiments substituting the complexhydrocarbon for most, if not all, of the required amount ofpetroleum-based asphalt binder for an asphalt mixture.

Furthermore, while the embodiments described above disclose a one to onecorrespondence (i.e., a replacement, substitution and/or combinationratio) between a weight of petroleum-based asphalt binder removed fromthe asphalt binder mixture and a weight of complex hydrocarbonsubstituted in its place, other replacements, substitution, and/orcombination ratios are contemplated as well. For example, the complexhydrocarbon may exhibit properties that allow a reduced amount of it tobe used in an asphalt binder mixture in comparison to a petroleum-basedasphalt binder. In other embodiments, however, increased amounts ofcomplex hydrocarbon may be required in relation to the petroleum-basedasphalt binder. The replacement, substitution, and/or combination ratiomay be determined by the input of the feedstock to the energy conversionprocessor 20, or the operation (e.g., temperature, pressure, residence)of the energy conversion processor. The replacement, substation, and/orcombination ratio may also be determined based on the end use of theasphalt mixture. For example, certain high-stress end uses (e.g.,highway construction) may require different ratios than less-stressfulend uses (e.g., automobile driveways or pedestrian paths). In someembodiments, the end use of the asphalt mixture dictates the amount ofcomplex hydrocarbon that may be used in the asphalt mixture.

According to some known systems, as mentioned above, polymer-basedasphalt binder additives are mixed with a petroleum-based asphalt binderto modify the material properties of the resulting asphalt mixture toconform to a standard set of values. The standard set of values maycomprise performance criterion set by a standards body. The materialproperties of petroleum-based asphalt binders are partially dependent onthe material properties of the crude oil from which the binders arederived. As the material properties of crude oil can vary substantiallybased on a number of factors (e.g., extraction method utilized,geographic source of the crude oil, etc.), the material properties ofthe binder derived therefrom can vary as well. Accordingly, thepolymer-based asphalt binder additives function to ensure that theasphalt mixture they are introduced into conforms to a standard set ofvalues for the material properties, regardless of the materialproperties of the crude oil used to derived the binder. Polymer-basedasphalt binder additives may account for between 1% and 20% by weight ofthe asphalt binder mixture, and in some embodiments between 2% and 10%by weight of the asphalt binder mixture, while in still in otherembodiments they may account for less than 5% by weight. In someembodiments, the complex hydrocarbon may comprise between 2% and 98% byweight of the asphalt binder mixture, while in others it may comprisebetween 1% and 25%, and while in still others it may comprise greaterthan 5% by weight.

In some embodiments, the complex hydrocarbon may be mixed with a reducedratio of a polymer-based asphalt binder additive and the othercomponents of the mixture to form an asphalt binder mixture. Thus, insome embodiments, the complex hydrocarbon may reduce the amount ofpolymer-based asphalt binder additive needed in the asphalt, while inother embodiments the complex hydrocarbon may function as a substitutefor at least a portion of the polymer-based asphalt binder additive.

In embodiments where the complex hydrocarbon functions, at least inpart, as a substitute for the polymer-based asphalt binder additive, theratio of the polymer-based asphalt binder additive may be in the rangeof 1% to 20% by weight to the other components of the asphalt bindermixture, while in other embodiments it may be less than 5% by weight. Inone embodiment, the ratio of the polymer-based asphalt binder additivemay be about 3%. The ratio of the complex hydrocarbon to the othercomponents of the asphalt binder mixture may be varied to coincide withthe reduced ratio of polymer-based asphalt binder additive. For example,if the polymer-based asphalt binder additive ratio in a previous asphaltbinder mixture was 12% and in a replacement asphalt binder mixture it is5%, an amount of complex hydrocarbon equal to 7% by weight will bepresent in the replacement asphalt binder mixture. Reduction in theamount of polymer-based asphalt binder additive utilized in asphaltbinder mixtures is beneficial as the cost of the additive per unitweight is significantly greater than the complex hydrocarbon and thepetroleum-based asphalt binder.

While the substitution of the complex hydrocarbon for polymer-basedasphalt binder additives and petroleum-based asphalt binders has beendescribed separately above, other embodiments contemplate the reductionof the amount of both the additive and the binder and the addition ofthe complex hydrocarbon. Although specific mention has been made toranges of the ratio of the hydrocarbon mixture to other components inthe asphalt binder mixture, they should not be construed as limiting. Tothe contrary, any variety of ranges may be utilized and the rangespresented herein are intended to be illustrative only. Furthermore, someembodiments may utilize the complex hydrocarbon for a completesubstitute of the traditional, petroleum-based asphalt binder.

In embodiments utilizing at least a portion of the complex hydrocarbonin a traditional asphalt binder mixture, marked improvements arerecognized over other asphalt binder mixtures which comprise apetroleum-based asphalt binder, aggregate, and polymer-based asphaltbinder additives. For example, in traditional petroleum-based asphaltbinder mixtures, dispersing the polymer-based asphalt binder additivestherein requires substantial mixing efforts in both time and the shearforce required to adequately disperse the additive. However, addition ofthe complex hydrocarbon reduces the duration of both the mixingoperation and the shear force required to disperse the polymer additive.Furthermore, the complex hydrocarbon may increase adhesion between thecomponents of the asphalt binder mixture and the aggregate that issubsequently combined with the mixture.

In some embodiments, the material properties of the complex hydrocarbongenerated by the energy conversion processor 20 are similar to those ofcoal tar pitch. Coal tar pitch is one of the byproducts produced whencoal is carbonized to produce coke or gasified to produce coal gas.While coal tar pitch may be used as an ingredient of an asphalt bindermixture, it contains heavy metals like mercury or cadmium. In contrast,the complex hydrocarbon may contain only trace amounts, if at all, ofheavy metals. Moreover, coal tar pitch is generated by anenergy-intensive process (e.g., carbonizing of coal) resulting inincreased expense when compared to the generation of the complexhydrocarbon by the energy conversion processor 20.

Asphalt (i.e., aggregate and an asphalt binder mixture comprising one ormore of: petroleum-based asphalt binder, polymer-based asphalt binderadditives, and the complex hydrocarbon) including the complexhydrocarbon is believed to possess markedly better properties thanasphalt which does not include the complex hydrocarbon due to theinclusion of the complex hydrocarbon. Asphalt binder containing thecomplex hydrocarbon generated by the energy conversion processor 20 hasbeen analyzed. A typical asphalt binder that did not contain the complexhydrocarbon, but which was still comprised of the same type ofpetroleum-based asphalt binder and polymer-based asphalt binderadditives typically receives a rating of “compliant” or “highcompliance” utilizing Dynamic Shear Rheometer (DSR) testing. A sample ofasphalt binder comprising a complex hydrocarbon generated by the energyconversion processor 20, a petroleum-based asphalt binder additive, anda polymer-based asphalt binder additive received a rating of “excessivecompliance” on the DSR apparatus, a markedly better rating than “highcompliance” indicating more desirable Theological properties.

In some embodiments, the asphalt containing an asphalt binder mixtureincluding the complex hydrocarbon is used in paving operations (e.g.,constructions of roads, parking lots, etc.), while in others it may beused in roofing products (e.g., asphalt shingles or roofing tarsubstitutes) or as a filler for cracks in asphalt surfaces. When used inpaving operations and as a crack filler, the complexhydrocarbon-containing asphalt mixture may exhibit improved rigidity inhot-weather conditions and increased elasticity in cold-weatherconditions. It has been found that the complex hydrocarbon possessedtenacious adhesion to surfaces which may portend to its use as a crackfiller in asphalt surfaces.

In the embodiment depicted in FIG. 10, a multi-chambered dual-cylinderpump pumps the waste stream into the energy conversion processor 20 andextracts the complex hydrocarbon (referred to as “fuel” in relation toFIGS. 1-8) therefrom. For purposes of discussion with regards to theslurry pump, the material extracted from the energy conversion processor20 (i.e., the complex hydrocarbon) will be referred to as an “effluent”.

With reference now to FIG. 10, a schematic view of a multi-chamberedpumping system (referred to generally as 100) is presented in accordancewith one embodiment of the present invention. Slurry is supplied to theslurry pumping system 100 from solid/liquid separator 14 and effluent isdischarged to the filter/processor 22. Both the solid/liquid separator14 and the filter/processor 22 may be open to the atmosphere andconsequently at or near atmospheric pressure, or they may be enclosedand maintained at another suitable pressure. In the embodiment depictedin FIG. 10, slurry is provided to the solid/liquid separator 14 by thewaste source 15. Included in the waste source 15 are the animal wastesand other liquids collected from the manure pit 12 (depicted in FIG. 1).While specific mention is made herein to the use of slurry as sourcesubstance for the multi-chambered pumping system 100, the pumping systemis not limited to the pumping of slurry. To the contrary, the pumpingsystem 100 may pump a variety of liquids or other substances containingsolids.

In some embodiments, the solid/liquid separator 14 may be positionedsuch that slurry is able to drain from the solid/liquid separator andinto other portions of the slurry pumping system 100 with only the aidof gravity. In one embodiment, pumps or conveyors may also be used inaddition to or instead of gravity to transport the slurry from thesolid/liquid separator 14. As used herein, the term “transport” isutilized to describe methods for moving mass from one location toanother, including, but not limited to: pumping, gravity, auger,conveyor, and the like.

For the purposes of discussion herein, the slurry provided by thesolid/liquid separator 14 is referred to as a “source substance”.

As seen in FIG. 10, the pump system 100 includes an input portion 108and an effluent portion 138. The input portion 108 includes an inputcylinder 110 having an inner diameter. Source substance input valve 202controls the flow of source substance from the solid/liquid separator 14into a input process section 112 of the input cylinder 110 through aninput cylinder input port 124. An input piston 116 separates the inputprocess section 112 from a fluid section 114. Attached to the inputpiston 116 is an input cylinder guide rod 118. The input cylinder guiderod 118 extends through a portion of the fluid section 114 and has afirst diameter associated therewith. Working fluid enters and exits thefluid section 114 of the input cylinder 110 through inlet and exhaustports 122.

As the input piston 116 moves along a longitudinal axis of the inputcylinder 110, the volumes of the input process section 112 and fluidsection 114 change in volume in inverse relation to one another. Sourcesubstance will flow into the input process section 112 (provided asupply of slurry is available from the solid/liquid separator 14) whenthe pressure of the working fluid is less than the pressure of thesource substance. Conversely, source substance will flow out of theinput process section 112 (provided a fluid communication means isavailable) when the pressure of the source substance is less than thepressure of the working fluid in the fluid section 114.

The longitudinal position of the input cylinder guide rod 118 relativeto a fixed point can be measured and monitored in some embodiments by aninput cylinder LVDT (linear variable differential transducer) 126. Inother embodiments, different mechanisms (e.g., string pots) may be usedto monitor the linear position of the input cylinder guide 118.

Seals or rings (not shown) may surround the input piston 116 and preventsource substance or working fluid from coming into contact with eachother as the piston moves along the longitudinal axis of the inputcylinder 110. Additionally the components comprising the input portion108 of the pump system 100 may be formed from any number of suitablematerials (e.g., metal).

The effluent portion 138 of the pump system 100 includes an effluentcylinder 140 having an inner diameter. In some embodiments, the innerdiameter of the effluent cylinder 140 and the input cylinder 110 aresubstantially equal, while in other embodiments they may differ by asmall amount, (e.g. less than a tenth or quarter of an inch). Effluententers and exits an effluent process section 152 of the effluentcylinder 140 through an effluent cylinder input port 164. An effluentpiston 156 separates the effluent section from a fluid section 154.Attached to the effluent piston 156 is an effluent cylinder guide rod158. The effluent cylinder guide rod 158 extends through a portion ofthe fluid section 154 and has a second diameter associated therewith.Working fluid enters and exits the fluid section 154 of the effluentcylinder through inlet and exhaust ports 162.

The longitudinal position of the effluent cylinder guide rod 158relative to a fixed point can be measured and monitored in someembodiments by an input cylinder LVDT (linear variable differentialtransducer) 166. In other embodiments, different mechanisms (e.g.,string pots) may be used to monitor the linear position of the effluentcylinder guide 158.

Seals or rings (not shown) may surround the effluent piston 156 andprevent effluent or working fluid from coming into contact with eachother as the piston moves along the longitudinal axis of the effluentcylinder 140. Additionally the components comprising the effluentportion 138 of the pump system 100 may be formed from any number ofsuitable materials (e.g., metal).

Connecting the fluid sections 114 and 154 of the input cylinder 110 andthe effluent cylinder 140 are fluid connection components (e.g., pipingor hoses) that provide fluid communication between the fluid sections114 and 154. One or more valves (not shown) control the flow of workingfluid between the fluid sections 114 and 154 and a working fluid pump170 and associated reservoir (not shown). As discussed in greater detailbelow, the pressure associated with output of effluent from the energyconversion processor is utilized to transfer working fluid between thefluid sections 114 and 154 in order to reduce the amount of workingfluid that is provided by the working fluid pump 170 to pump sourcesubstance from the input cylinder 110 into energy conversion process 20.The utilization of the pressure of the effluent to aid in pumping sourcesubstance into the energy conversion processor significantly reduces thepower consumption of the working fluid pump 170.

Returning now to the pumping system 100, source substance exit valve 304controls the flow of source substance from the input process section112. Upon closing of the source substance input valve 302 and opening ofthe source substance exit valve 304, source substance can travel throughvarious pipes or other fluid communication systems to an input 404 ofthe energy conversion processor 20. The source substance then travelsthrough the energy conversion processor 20 before exiting as effluent atan output 402 of the energy conversion processor. As described above,once inside the energy conversion processor 20, the source substance(i.e., slurry) may be subjected to elevated temperature or pressure forsome duration and converted to the above-mentioned effluent.

An effluent exit valve 308 controls the flow of effluent from the energyconversion processor 20 through the output 402 therein to an effluentinlet port 164 to the effluent section 152 of the effluent cylinder 140.Upon opening of the effluent exit valve 308 and closing of an effluentdump valve 306, effluent is able to flow from the energy conversionprocessor 20 to the effluent section 152, thus raising the effluentpiston 156 and displacing working from the fluid section 154 of theeffluent cylinder 140.

The amount of heat required to be input to the energy conversionprocessor 20 is reduced through the use of a heat exchanger 310. In someembodiments, the slurry passes through the heat exchanger 310 beforeentering the energy conversion processor 20. Effluent subsequentlypasses through the heat exchanger after exiting the energy conversionprocessor 20. The heat exchanger 310 transfers heat from the effluentexiting the energy conversion processor 20 to the slurry entering theenergy conversion processor, thus reducing the amount of heat that theenergy conversion processor must provide to the slurry.

The first diameter associated with input cylinder guide rod 118 is lessthan that of the second diameter associated with the effluent cylinderguide rod 158. The difference in diameters between the guide rods 118and 158 serves to compensate for a pressure difference between apressure associated with a source substance input into the energyconversion processor 20 from the input cylinder 110 and a pressureassociated with the effluent contained within the energy conversionprocessor and output to the effluent cylinder 140. According to otherembodiments, the first diameter associated with the input cylinder guiderod 118 is substantially equal to that of the second diameter associatedwith the effluent cylinder guide rod 158 and additional pressurizedworking fluid is provided by working fluid pump 170.

Referring now to FIG. 11, a flow diagram 1100 is provided thatillustrates a method for pumping a source substance (e.g., a slurry)into a energy conversion processor and receiving an effluent as outputfrom the energy conversion processor, in accordance with anotherembodiment. In operation of the pumping system, there are two distinctcycles. A first cycle includes receiving 1110 source substance into aninput process section of the input cylinder and a correspondingdischarging 1120 of effluent from an effluent process section of theeffluent cylinder. The second cycle includes discharging 1130 of sourcesubstance from the input process section of the input cylinder into theenergy conversion processor and corresponding receiving 1140 of theeffluent in the effluent process section of the effluent cylinder fromthe energy conversion processor. Accordingly, while the steps depictedin blocks 1110 and 1120 are depicted as separate operations, they occursubstantially simultaneously and may be performed simultaneously.Likewise, the steps depicted in blocks 1130 and 1140 occur substantiallysimultaneously and may accordingly be performed as such.

For purposes of discussion herein, it will be assumed that the energyconversion processor is acting in a steady-state operation wherein thesource substance level within the energy conversion processor is at itsoperating capacity. During initial startup of the pump system when theenergy conversion processor is substantially empty or the sourcesubstance level is below operating capacity, multiple pumping operationsby the input cylinder alone (e.g., without corresponding withdrawal ofeffluent from the energy conversion processor) may be required to“charge” the energy conversion processor with source substance. In someembodiments, the pumping operation may cease after the charging of theenergy conversion processor is complete to allow the energy conversionprocessor the requisite time to change the chemical composition of thesource substance into the effluent. Further, it is assumed that themethod described below, which begins with the filing of the inputcylinder, that the effluent cylinder has already been filled witheffluent output from the energy conversion processor.

The method depicted in FIG. 11 begins with the receiving 1110 of sourcesubstance into the input process section of the input cylinder. Asdescribed above, one example of the source substance is a slurry. Thesource substance may be conveyed into the input process section by theforce of gravity, wherein a source of the source substance is positionedabove the input to the input process section. In other embodiments,different conveying mechanisms may be used to feed source substance intothe input process section, such as augers or conveyers. One or morevalves may control the flow of source substance into the input processsection, and accordingly are opened to permit the flow source substanceinto the input process section. After the input process section has beenfilled with source substance, the one or more valves are closed.

Effluent is discharged 1120 from the effluent process section of theeffluent cylinder into an effluent vat in fluid communication therewith.To discharge effluent from the vat, one or more valves controlling theoutput from the effluent process section of the effluent cylinder areopened, thus permitting the effluent to travel to the effluent vatthrough any suitable fluid connection components (e.g., pipes, hoses,troughs, etc.). The effluent is then subjected to additional processes(e.g., separation or drying operations).

As effluent is discharged from the effluent process section, theeffluent cylinder piston travels along the longitudinal axis of theeffluent cylinder, thus reducing the volume of the effluent processsection and increasing the volume of the fluid section. Additionalworking fluid is directed into the fluid section from the inputcylinder's fluid section as the input process section of the inputcylinder is filled with source substance. One or more valves may controlthe flow of working fluid between the fluid sections of the input andeffluent cylinders. After the effluent has discharged from the effluentprocess section, the one or more valves controlling the output from theeffluent process section are closed.

The source substance is pumped or discharged 1130 into the energyconversion processor from the input process section of the inputcylinder. Coincident with the initiation of pumping the source substanceinto the energy conversion processor, a valve controlling the flow ofsource substance along a pipe or hose into the energy conversionprocessor is opened. To pump the source substance from the input processsection, working fluid in the fluid section acts against the inputpiston, thus forcing it to move along the longitudinal axis of the inputcylinder. When the pressure of the working fluid in the fluid sectionsexceeds that of the source substance in the input process section, thevolume of the input process section begins to decrease as the workingfluid moves the input piston.

In some embodiments, the source substance is input into the energyconversion processor at an elevated pressure, and accordingly is pumpedat this elevated pressure into the energy conversion processor. A guiderod is attached to the input piston and extends through the fluidsection thus reducing the surface area of the input piston on which theworking fluid is able to act. Accordingly, the pressure of the workingfluid exceeds the pressure of the source substance being pumped out ofthe input process section. Working fluid is supplied to the fluidsection of the input cylinder from the fluid section of the effluentcylinder, as described in greater detail below. Working fluid is alsoprovided by the working fluid pump. In embodiments that utilizehydraulic fluid as a working fluid, the working fluid pump is ahydraulic pump.

Effluent is received 1140 into the effluent process section of theeffluent cylinder from the energy conversion processor. As describedabove, effluent is output from the energy conversion processor at anelevated pressure, often slightly less than that of source substanceinput into the energy conversion processor. The decrease in pressure isa result of numerous factors including, but not limited to: frictionallosses in the energy conversion processor or chemical changes occurringin the source substance.

In order to receive effluent into the effluent process section, one ormore valves are opened that control the flow of effluent into theeffluent process section. In some embodiments, the flow of effluent fromthe energy conversion processor to the effluent process reaction iseffectuated by one or more pipes, hoses, or tubes.

One or more valves controlling the flow of working fluid into and out ofthe fluid section of the effluent cylinder may be opened. As theeffluent fills the effluent process section, it acts against theeffluent piston, which in turn acts against the working fluid. The guiderod attached to effluent piston extends through the fluid section, thusreducing the surface area of the piston adjacent to the fluid section.Accordingly, when the effluent acts against one side of the piston, thepressure associated with the working fluid on the other side of thepiston is greater than the pressure of the effluent. In hydraulicsystems, this concept is sometimes referred to as pressureamplification. As the pressure is determined by the force applieddivided by the surface area of the piston, a larger guide rod reducesthe surface area of the piston and increases the pressure amplification.

In some embodiments, the inner diameter of the input and effluentcylinders are substantially equal and the effluent cylinder guide rodhas a larger diameter than the input cylinder guide rod. Accordingly,when the effluent acts upon the effluent piston, the pressure of theworking fluid in the corresponding fluid section is greater than thepressure associated with the effluent. As effluent fills the effluentprocess section and acts against the piston, working fluid is directedfrom the fluid section via one or more pipes or hoses to the fluidsection of the input cylinder.

As described above, the diameters of the input cylinder guide rod andthe effluent cylinder guide are operable to compensate for thedifference in pressure of the source substance input into the energyconversion processor and effluent output from the energy conversionprocessor. The difference in diameters between the guide rods are sizedto amplify the pressure of the working fluid in the fluid section of theeffluent cylinder to the pressure required in the fluid section of theinput cylinder to pump source substance into the energy conversionprocessor at the desired pressure. To accomplish this, the diameter ofthe effluent cylinder guide rod is larger than the input cylinder guiderod. In other embodiments, the diameters of the effluent cylinder guiderod and the input cylinder guide rod are substantially equal. In theseembodiments, additional pressurized working fluid is supplied to accountfor the pressure differential between the effluent output from theenergy conversion processor and the source material input to the energyconversion processor.

As the diameter of the effluent cylinder guide rod is larger than theinput cylinder guide rod in some embodiments, the amount of workingfluid directed from the fluid section of the effluent cylinder to thefluid section of the input cylinder is less than that required to pumpthe source substance. Accordingly, additional working fluid is suppliedby the working fluid pump and associated reservoir when source substanceis pumped from the input cylinder and effluent is simultaneouslyreceived in the effluent cylinder. The volume of the additional workingfluid required is approximately equal to the difference in volumebetween the two fluid sections caused by the differently sized guiderods. However, in some embodiments the diameters of the guide rods aresubstantially equal and accordingly additional pressurized working fluidis required over that required for the other described embodiment.

In the other phase of the pumping cycle, discussed in relation toreceiving 1110 and discharging 1120, working fluid is directed from thefluid section of the input cylinder to the fluid section of the effluentcylinder. As the fluid section in the effluent cylinder is lesser involume than that of the input cylinder fluid section, the excess workingfluid is directed to a reservoir. Upon initiation of the other phase ofthe pumping cycle, the working fluid pump uses working fluid containedin the reservoir.

In some embodiments, the heat exchanger described above may be utilized.The heat exchanger transfers heat between the effluent output from theenergy conversion processor and the source substance input to the energyconversion processor. Accordingly, source substance passes through theheat exchanger before entering the energy conversion processor andeffluent passes through the heat exchanger after exiting the energyconversion processor. The heat exchanger is useful in embodimentswherein the source substance is subjected to an elevated temperature inthe energy conversion processor, and effluent is subsequently outputfrom the energy conversion processor at an elevated temperature. Theutilization of the heat exchanger permits a portion of the heatassociated with the effluent to be transferred to the source substance,thus reducing the amount of heat required for operation of the energyconversion processor.

While the invention has been described in terms of various specificembodiments, those skilled in the art will recognize that the inventioncan be practiced with modification within the spirit and scope of theclaims.

This written description uses examples to disclose the invention,including the best mode, and also to enable any person skilled in theart to practice the invention, including making and using any devices orsystems and performing any incorporated methods. The patentable scope ofthe invention is defined by the claims, and may include other examplesthat occur to those skilled in the art. Such other examples are intendedto be within the scope of the claims if they have structural elementsthat do not differ from the literal language of the claims, or if theyinclude equivalent structural elements with insubstantial differencesfrom the literal languages of the claims.

1. A process for manufacturing a complex hydrocarbon, the processcomprising: receiving animal waste containing solids and liquids fromanimal confinements or other concentrated animal waste sources;separating the liquids and solids into a solid waste stream and a liquidwaste stream, the solid waste stream having a lower percentage ofliquids than the liquid waste stream; controlling an amount of moisturein the solid waste stream such that the amount of moisture in the solidwaste stream is compatible with an energy conversion process; feedingthe moisture controlled solid waste stream into the energy conversionprocess, wherein a specific temperature and pressure associated with theenergy conversion process converts the moisture controlled solid wastestream into a complex hydrocarbon; and utilizing the complex hydrocarbonas a portion of an asphalt binder mixture.
 2. The process of claim 1wherein the specific temperature and pressure associated with the energyconversion process results in converting the moisture controlled solidwaste stream into a complex hydrocarbon having material propertiessimilar to a petroleum-based asphalt binder.
 3. The process of claim 1wherein utilizing the complex hydrocarbon as a portion of the asphaltbinder mixture comprises utilizing the complex hydrocarbon as asubstitute for at least a portion of a polymer-based asphalt binderadditive in the asphalt binder mixture.
 4. The process of claim 1wherein utilizing the complex hydrocarbon as a portion of an asphaltbinder mixture comprises utilizing the complex hydrocarbon as asubstitute for at least a portion of a polymer-based asphalt binderadditive in a petroleum-based asphalt binder mixture.
 5. The process ofclaim 1 wherein utilizing the complex hydrocarbon as a portion of anasphalt binder mixture further comprises mixing the asphalt bindermixture with a polymer-based asphalt binder additive to form the asphaltbinder mixture.
 6. The process of claim 1 wherein utilizing the complexhydrocarbon as a portion of an asphalt binder mixture further comprisesmixing an asphalt binder mixture comprising the complex hydrocarbon, apolymer-based asphalt binder additive, and a petroleum-based asphaltbinder, wherein the complex hydrocarbon comprises between 2% and 98% byweight of the asphalt binder mixture.
 7. The process of claim 1 whereinutilizing the complex hydrocarbon as a portion of an asphalt bindermixture further comprises mixing an asphalt binder mixture comprisingthe complex hydrocarbon, a polymer-based asphalt binder additive, and apetroleum-based asphalt binder, wherein the polymer-based asphalt binderadditive comprises between 2% and 20% by weight of the asphalt bindermixture.
 8. The process of claim 1 wherein utilizing the complexhydrocarbon as a portion of an asphalt binder mixture further comprisesmixing an asphalt binder mixture comprising the complex hydrocarbon, apolymer-based asphalt binder additive, and a petroleum-based asphaltbinder, wherein the polymer-based asphalt binder additive comprises lessthan 5% by weight of the asphalt binder mixture and the complexhydrocarbon comprises greater than about 5% by weight of the asphaltbinder mixture.
 9. The process of claim 1 further comprising injectinghydrogen into the energy conversion process.
 10. A process formanufacturing an asphalt binder, the process comprising: feeding amoisture controlled solid waste stream comprising animal waste into anenergy conversion process; controlling temperatures and pressuresassociated with the energy conversion process such that the moisturecontrolled solid waste stream is converted into a complex hydrocarbonoperable as a portion of an asphalt binder mixture and; utilizing thecomplex hydrocarbon as a portion of an asphalt binder mixture.
 11. Theprocess of claim 10 further comprising, prior to feeding the moisturecontrolled solid waste stream into the energy conversion process,controlling an amount of moisture in the solid waste stream such thatthe amount of moisture in the solid waste stream is compatible with theenergy conversion process.